101492-4000 ZEXEL 9 400 614 463 BOSCH INJECTION-PUMP ASSEMBLY 9400614463 1014924000 8972231690

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 463 9400614463

ZEXEL 101492-4000 1014924000

ISUZU 8972231690 8972231690

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Buy INJECTION-PUMP ASSEMBLY 101492-4000 zexel genuine, new aftermarket engine parts with delivery

Include in #1:

106682-4483 as _

106682-4484

Cross reference number

BOSCH 9 400 614 463 9400614463

ZEXEL 101492-4000 1014924000

ISUZU 8972231690 8972231690

Zexel num

Bosch num

Firm num

Name

101492-4000

9 400 614 463

8972231690 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1 K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 3.3 3.25 3.35

Rack position
Point A R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 8.7

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 51.5 50.5 52.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.4+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 11.5 9.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting
----------
K=15
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=21deg+-5deg b=13deg+-5deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'V' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(210deg)

Information:

PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
****Parts Stock ****
Rework the following engines in dealer parts stock:
3512 Engine Arrangement 0R3982, 0R9844, 10R6700 - EEE00102-EEE00149
3516 Engine Arrangement Number 0R3953, 0R3983, 0R9845, 10R2854, 10R6702, 20R2775, 20R5421 - WE300101-WE300159, WE300161-WE300173, WE300175-WE300178, WE300180-WE300188
3508 Engine Arrangement Number 0R3950, 0R3951, 0R8550, 0R8551, 0R8553, 0R9840, 0R9841, 0R9842, 10R5596, 10R9195 - HEE00101-HEE00192, HEE00196-HEE00223, HEE00227-HEE00230
3516 Engine Arrangement Number 10R2853, 20R2776, 20R3194, 20R3537, 20R6114, 20R6115, 20R1116 - DE300101-DE300181, DE300183-DE300200, DE300202-DE300208
3512 Engine Arrangement Number 10R9209, 20R2674 - EEZ00101-EEZ00127, EEZ00130-EEZ00136, EEZ00138-EEZ00143
3524 Engine Arrangement Number 10R7929 - XEE00101-XEE00139
3516 Engine Arrangement Number 20R7272 - AW300101-AW30109
3512 Engine Arrangement Number 20R3658 - EEK00101
Check valve lash setting on each cylinder of the engine using SENR2362, Valve Lash Check. If found out of spec then adjust using SENR2362, Valve Lash Bridge Adjustment. Use SENR2362, Fuel Injector Timing to verify correct injector lash.
****Affected Product****
This program applies only if the Affected Product is equipped with one of the following Reman Engines:
3512 Engine Arrangement 0R3982, 0R9844, 10R6700 - EEE00102-EEE00149
3516 Engine Arrangement Number 0R3953, 0R3983, 0R9845, 10R2854, 10R6702, 20R2775, 20R5421 - WE300101-WE300159, WE300161-WE300173, WE300175-WE300178, WE300180-WE300188
3508 Engine Arrangement Number 0R3950, 0R3951, 0R8550, 0R8551, 0R8553, 0R9840, 0R9841, 0R9842, 10R5596, 10R9195 - HEE00101-HEE00192, HEE00196-HEE00223, HEE00227-HEE00230
3516 Engine Arrangement Number 10R2853, 20R2776, 20R3194, 20R3537, 20R6114, 20R6115, 20R1116 - DE300101-DE300181, DE300183-DE300200, DE300202-DE300208
3512 Engine Arrangement Number 10R9209, 20R2674 - EEZ00101-EEZ00127, EEZ00130-EEZ00136, EEZ00138-EEZ00143
3524 Engine Arrangement Number 10R7929 - XEE00101-XEE00139
3516 Engine Arrangement Number 20R7272 - AW300101-AW30109
3512 Engine Arrangement Number 20R3658 - EEK00101
Check valve lash setting on each cylinder of the engine using SENR2362, Valve Lash Check. If found out of spec then adjust using SENR2362, Valve Lash Bridge Adjustment. Use SENR2362, Fuel Injector Timing to verify correct injector lash.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all engines reworked from dealer parts stock.
This is a 4 hour job for a 3508
An additional 2 hours for a 3512
An additional 4 hours for a 3516
An additional 8 hours for a 3524
Include the engine serial number(s) of the Reman engine(s) that was/were reworked in the claim.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-250 hrs,
0-3 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
4.0-hours for a 3508.
An additional 2 hours for a 3512
An additional 4 hours for a 3516
An additional 8 hours for a 3524
Part age/hours is based on engine age/hours.
Include the engine serial number of the Reman engine that was reworked in the claim.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.